Electrowinning Cell Mode Switching for Power Price Response
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Solution Overview
Problem
Electrowinning plants face challenges in managing operation to achieve cost-effectiveness and profitability due to volatility in metal and electricity markets, leading to inefficiencies in electricity consumption and production.
Innovation Solution
Implementing a method and system that allows electrochemical cells to switch between charge and discharge modes based on electricity availability and cost, reducing metal from an oxidized state to zero valence and vice versa to generate electricity, thereby optimizing energy usage and revenue generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If electrowinning plants reduce electricity consumption during high electricity prices, then cost-effectiveness improves, but production of product metal decreases
Solution Approach 1:
The system dynamically switches electrochemical cells between charge mode and discharge mode based on real-time electricity pricing signals. During high electricity price periods, cells operate in discharge mode to generate electricity rather than consume it, while during low price periods, cells operate in charge mode to produce metal. This dynamic operational flexibility resolves the contradiction by allowing the system to adapt its energy consumption profile to market conditions.
Solution Approach 2:
The system changes the operational parameter of electrochemical cells from unidirectional metal production to bidirectional operation (charge and discharge modes). By controlling the electrochemical reactions to proceed in opposite directions based on electricity price parameters, the system can reduce net electricity consumption during high-price periods while maintaining overall production targets through extended charge operation during low-price periods.
2Productivity
If electrowinning plants operate continuously to maximize metal production, then productivity improves, but electricity cost increases due to market volatility
Solution Approach 1:
The system implements periodic switching between charge and discharge operations based on electricity price cycles. Rather than continuous charge operation, the system alternates between producing metal (charge mode) and generating electricity (discharge mode) in response to periodic price variations. This periodic action allows the system to capture value from both metal and electricity markets while managing overall energy costs.
Solution Approach 2:
The electrochemical cells are designed to perform multiple functions: they can produce metal during charge mode and generate electricity during discharge mode. This multi-functionality allows the same equipment to contribute to both metal production targets and electricity revenue generation, resolving the contradiction between maximizing productivity and minimizing energy cost by allowing the system to switch functions based on market conditions.
3Loss of energy
If electrowinning plants switch between charge and discharge modes, then cost-effectiveness improves through market volatility management, but operational complexity increases
Solution Approach 1:
The system incorporates feedback mechanisms that monitor electricity price signals and automatically adjust the operational mode of electrochemical cells. The control system receives feedback on market conditions and responds by switching between charge and discharge modes, eliminating the need for complex manual operational decisions. This automated feedback control manages operational complexity while capturing the benefits of market volatility.
Solution Approach 2:
The electrochemical cells inherently possess the capability to switch between charge and discharge modes based on applied electrical potential. The system leverages this self-service capability where the same electrochemical infrastructure performs both metal production and electricity generation without requiring separate dedicated equipment. This reduces operational complexity compared to having separate facilities for each function.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables electrowinning plants to effectively manage energy consumption and revenue generation by selectively switching between charge and discharge modes, enhancing cost-effectiveness and profitability amidst market volatility.
Implementation Method 1
a first electric current applied across the electrochemical cell reduces the metal from the oxidized state to a zero valence state
Implementation Method 2
oxidation of at least some of the metal from the zero valence state to the oxidized state generates a second electric current oppositely charged relative to the first electric current
Data Source
AI summary
Methods and systems of the present disclosure are generally directed to switching operation of one or more electrochemical cells of an electrowinning plant between a charge mode and a discharge mode. In the charge mode, the one or more electrochemical cells may reduce metal from an oxidized state to a zero valence state with a first electric current applied across the one or more electrochemical cells. In the discharge mode, the one or more electrochemical cells may oxidize at least some of the metal from the zero valence state to the oxidized state to generate a second electric current, oppositely charged relative to the first electric current, to generate electricity (e.g., for delivery to the grid). Operation of the one or more electrochemical cells of the electrowinning plant may be selectively changed between the charge mode and the discharge mode based on, for example, availability/cost of electricity from the grid.